Solar Installation System

ABSTRACT

A support frame for a solar panel comprises a channel member including a bottom panel, a front vertical panel extending upward from a front edge of the bottom panel, and a rear vertical panel extending upward from rear edge of the bottom panel. Front and rear support panels for engaging a bottom surface of the solar panel extend respectively from the upper ends of the front and rear vertical panels. The front and rear support panels lie in the same inclined plane. The support frame is secured to the roof structure by a clamping assembly.

BACKGROUND

The present invention relates to a solar installation system formounting solar panels or photovoltaic panels on industrial flat roofsand light-weight designed roofs.

Solar panels or photovoltaic panels convert solar energy intoelectricity and provide a promising means for meeting future energyneeds. Solar panels are usually mounted on the roof of buildings toallow the maximum exposure to sunlight and least interference to the useof the building itself. Conventional mounting methods typically requiresubstantial modifications to the roof structure that are usuallydifficult and time consuming to make. Solar panel installations oftenresult in leaks in the roof of a building due to improper sealing of theholes through the roof. Furthermore, some conventional mounting methodscan weaken the roof structure. Additionally, some mounting systems arenot suitable for situations where very high wind uplift loads areexpected.

There is a continuing need for a mounting system that makesinstallations simple and quick, that can withstand high wind upliftloads, and that does not impair the integrity of the roof structure.

SUMMARY

The present invention relates to a mounting system for mounting a solarpanel to a roof structure. The mounting system may be applied on top ofan existing roof structure, is capable of withstanding very high winduplift loads, can be easily and quickly installed, and does not impairthe structural integrity of the roof structure.

The mounting system includes a support frame to support a solar panel inan inclined position, a clamping system to secure the support frame tothe roof, and a waterproofing system to maintain the impermeability ofthe roofing system to water. The support frame comprises a channelmember including a bottom panel, a front vertical panel extending upwardfrom a front edge of the bottom panel, and a rear vertical panelextending upward from the rear edge of the bottom panel. Front and rearsupport panels for engaging a bottom surface of the solar panel extendrespectively from the upper ends of the front and rear vertical panels.The front and rear support panels lie in the same inclined plane.

The clamping system comprises a base member, an optional loaddistributing member and clamping bar. The base member includes a baseplate that fastens to the roof structure and a threaded rod that extendsupward from the base plate. The load distributing member and clampingbar overlap the bottom panels of two adjacent support frames. A clampingnut threads onto the threaded rod of the base member and tightensagainst the clamping bar.

The waterproofing system comprises a waterproof patch with an openingfor the threaded rod. The opening is preferably sized to snugly fit thethreaded rod. The waterproof patch covers the base plate of the basemember and may be bonded at its outer edges with the waterproof membraneof the roof structure. A sealing collar and waterproof nut are installedon the threaded rod to seal the opening around the threaded rod.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the solar panel mounting systemaccording to one exemplary embodiment.

FIG. 2 is a perspective view of a support frame for the solar panelmounting system.

FIG. 3 is an exploded perspective view of the solar panel mountingsystem.

FIG. 4 is a plan view of the solar panel mounting system.

FIGS. 5A-5D illustrate a base member for the solar panel mounting systembeing secured to a roof structure.

FIG. 6 illustrates a cross-section of a typical roof structure showingthe base member and a portion of the support frame.

DETAILED DESCRIPTION

Referring now to the drawings, and particularly to FIG. 1, a mountingsystem 10 according to one exemplary embodiment is shown. The mountingsystem 10 is used to mount a solar panel 100 to a generally flat roofstructure and is designed to carry high loads. The mounting system 10comprises a support frame 12 for supporting solar panels in an inclinedposition, a clamping assembly 30 for securing the support frame to aroof structure, and a waterproofing system 40 to prevent infiltration ofwater into the roof structure.

FIG. 2 illustrates an exemplary support frame 12. The support frame 12is made from a single aluminum sheet that is bent to form an elongated,generally U-shaped support structure. The support frame 12 is designedto distribute loads over a large area of the roof and to withstand veryhigh wind uplift loads. The support frame 12 includes a bottom panel 14that rests on the roofing structure, a front vertical panel 16, a rearvertical panel 18, a front support panel 20 with an up-turned flange 22,and a rear support panel 24. The bottom panel 14 lies flat against theroof structure and distributes load over a relatively large area of theroof structure. The front and rear vertical panels 16,18 extendgenerally perpendicularly from the bottom panel 14. If the roof isinclined, however, the front and rear vertical panels 16, 18 may bedisposed at an angle relative to the bottom panel 14 such that the frontand rear panels 16, 18 lie in vertical planes. The front and rearvertical panels 16, 18 function to deflect wind and help reduce winduplift on the solar panels 100. The front support panel 20 and rearsupport panel 24 are disposed at an angle relative to the front and rearvertical panels 16, 18, respectively. The front and rear support panels20, 24 lie in an inclined plane. The angle of the inclined planerelative to a horizontal plane is selected to maximize exposure of thesolar panel 100 to solar radiation. The panels 14-24 all extend in thesame longitudinal direction, which is parallel to the inclined plane ofthe solar panel 100.

As shown in FIG. 2, the solar panel 100 rests on top of the front andrear support panels 20, 24 in an inclined position. The up-turned flange22 on the front support panel 20 prevents the solar panel 100 fromsliding off of the support frame 12. Any suitable means may be used forsecuring the solar panel 100 to the support frame 12. In the exemplaryembodiment, clamps 110 are used to secure the solar panel 100 to thesupport frame 12. One advantage of clamps 110 is that no drilling ormodification of the solar panels 100 is required. Thus, the solar panels100 can be installed and removed without causing any damage to the solarpanels 100.

The support frame 12 provides an air flow channel below the bottomsurface of the solar panel 100 when the solar panel 100 is installed onthe support frame 12, which aids in cooling the solar panels 100. Thesupport frame 12 distributes the load of the solar panel 100 over alarge area of the roof structure and resists high wind uplift loads.

One or more clamping assemblies 30 (FIG. 3) secure the support frame 12to the roof structure. The basic elements of a clamping assembly 30include a base member 32, an optional load distributing member 37, and aclamping bar 38. The base member 32 fastens to the roof structure asdescribed below. The load distributing member 37 and clamping bar 38, incooperation with the base member 32, apply a clamping force to thebottom panel 14 to secure the support frame 12 to the roof structure. Ingeneral, the load distributing member 37 is used when there are highwind uplift loads, but may be omitted when only light wind uplift loadsare present. The load distributing member 37 distributes the clampingforce exerted by the clamping bar 38 and helps prevent metal fatigue atthe point where the clamping bar 38 would otherwise engage the bottompanel 14.

The base member 32 comprises a base plate 34 having a threaded rod 36extending upwardly therefrom. The threaded rod 36 can be welded to thebase plate 34, or secured to the base plate 34 by a threaded connection.The base member 32 is securely fastened to the roof structure usingscrews, anchors, or other suitable fastening means. The loaddistributing member 37 and clamping bar 38 each comprise a channel madeof aluminum or other strong but lightweight material. The loaddistributing member 37, when used, is arranged so the channel opensupward. The clamping bar 38 is arranged so that the channel opensdownward. The load distributing member 37 and clamping bar 38 arelowered onto the threaded rod 36 of the base member 32 so that thethreaded rod passes through aligned openings 40 in the load distributingmember 37 and clamping bar 38 respectively. The load distributing member37 and clamping bar 38 are secured in place by a clamping nut 42 thatthreads onto the end of the threaded rod 36 and tightens against the topsurface of the clamping bar 38

FIG. 4 illustrates how the clamping system 30 is used to secure thesupport frames 12 to a roof structure. The support frames 12 for two ormore solar panels 100 are aligned in row. The base members 32 arepositioned between adjacent support frames 12 and secured to the roofstructure as previously described. The load distributing members 37 andclamping bars 38 are placed so that they extend parallel to the frontand rear vertical walls 16, 18 and overlap two adjacent support frames12. When the clamping nut 42 is tightened, the load distributing member37 and clamping bar 38 are pressed firmly downward against the bottomplate 14 of the support frames 12. The force generated by the clampingbars 38 on the support frames is capable of resisting very high upliftloads.

FIGS. 5A-5D illustrate the installation of the base member 32. Afterdetermining the location of the base member 32, the base member 32 issecured to the roofing structure by self-tapping screws that screw intothe metal decking of the roof structure. (FIG. 5A). After the basemember 32 is installed, a fibrous backing material 44 is placed over thebase plate 34 (FIG. 5B). A waterproof patch 46 compatible with theexisting waterproof membrane on the roof structure is placed over thebacking material 44. (FIG. 5C). A sealing collar 48 is placed over thethreaded rod 36. A self-sealing nut 50 is then threaded onto thethreaded rod 36 and tightened to press the sealing collar firmly againstthe waterproof membrane (FIG. 5D). The outer periphery of the waterproofpatch can then be secured to the existing waterproof membrane of theroof by conventional means, such as waterproof adhesives, fusing, etc.

FIG. 6 illustrates a cross-section of a typical roof structure showingthe base member 32 and a portion of the support panel 12. The roofstructure includes a corrugated metal decking 102, a vapor barrier 103,an insulation layer 104, a waterproof membrane 105, and a finishinglayer 106. The base member 32 is installed on top of the waterproofmembrane 105 and is secured to the metal decking 102 by screws thatpenetrate through the roof structure. The waterproof patch 46 covers thebase plate 34 of the base member 32 and is bonded at its outer edges tothe waterproof membrane 105. Sealing collar 48 and nut 50 preventinfiltration of water around the threaded rod 36. The support frame 12is held down by the clamping bar 38 and clamping nut 42.

The exemplary embodiment provides one example of how the presentinvention may be used. However, the present invention is not intended tobe limited in any way to the specific details of the exemplaryembodiment and variations from the exemplary embodiment will be readilyapparent to those of skill in the art.

1. A support frame for supporting a solar panel on a roof, said supportframe comprising: an elongated channel member including a bottom panel,a front vertical panel extending upward from a front edge of the bottompanel, and a rear vertical panel extending upward from rear edge of thebottom panel; front and rear support panels for engaging a bottomsurface of the solar panel extending respectively from upper ends ofsaid front and rear vertical panels; and wherein said front and rearsupport panels are coplanar and lie in the same inclined plane.
 2. Thesupport frame of claim 1 wherein the front and rear vertical panels aredifferent heights.
 3. The support frame of claim 2 wherein the rearvertical panel is higher than the front vertical panel.
 4. The supportframe of claim 3 wherein the front and rear support panels extendoutwardly from the front and rear vertical panels.
 5. The support frameof claim 4 wherein the front support panel forms an acute angle with thefront vertical panel and the rear support panel forms an obtuse anglewith the rear vertical panel.
 6. The support frame of claim 1 furthercomprising a flange extending at a right angle from said front supportpanel for engaging a bottom edge of said solar panel and preventing thesolar panel from sliding.
 7. The support frame of claim 1 wherein theelongated channel, the front support panel, and the rear support panelare formed from a single sheet of material.
 8. The support frame ofclaim 1 wherein the front and rear vertical panels are made from solid,non-perforated sheets for deflecting wind.
 9. A clamping assembly forsecuring a support frame for a solar panel to a roof structure, saidclamping assembly comprising: a base member including a base plate to besecured to the roof structure and a threaded rod extending upwardly fromthe base member; an elongated clamping bar to extend over a portion ofsaid support frame to apply a clamping force to the support frame, saidclamping bar have an opening through which the threaded rod extends, anda clamping nut to thread onto an end of the threaded rod and to tightenagainst said clamping bar to generate said clamping force.
 10. Theclamping assembly of claim 9 wherein said clamping bar comprises aU-shaped channel opening downwards
 11. The clamping assembly of claim 10further comprising a load distributing member for interposing betweensaid clamping bar and said support frame to distribute clamping forcesover said support frame.
 12. The clamping assembly of claim 11 whereinthe load distributing member comprises a U-shaped channel openingupwards.
 13. A mounting system for mounting one or more solar panels toa roof structure, said mounting system comprising: a generally U-shapedsupport frame for supporting at least one solar panel in an inclinedposition above a roof structure: a clamping mechanism to secure thesupport frame to the roof structure, said clamping assembly comprising:a base member including a base plate adapted to be secured to the roofstructure and a threaded rod extending upwardly from the base member; anelongated clamping bar to extend over a portion of said support frame toapply a clamping force to the support frame, said clamping bar have anopening through which the threaded rod extends, and a clamping nut tothread onto an end of the threaded rod and to tighten against saidclamping bar to generate said clamping force.
 14. The mounting system ofclaim 13 wherein the front and rear vertical panels are differentheights.
 15. The mounting system of claim 14 wherein the rear verticalpanel is higher than the front vertical panel.
 16. The mounting systemof claim 15 wherein the front and rear support panels extend outwardlyfrom the front and rear vertical panels.
 17. The mounting system ofclaim 16 wherein the front support panel forms an acute angle with thefront vertical panel and the rear support panel forms an obtuse anglewith the rear vertical panel.
 18. The mounting system of claim 13further comprising a flange extending at a right angle from said frontsupport panel for engaging a bottom edge of said solar panel andpreventing the solar panel from sliding.
 19. The mounting system ofclaim 13 wherein the elongated channel, the front support panel, and therear support panel are formed from a single sheet of material.
 20. Themounting system of claim 13 wherein the front and rear vertical panelsare made from solid, non-perforated sheet material for deflecting wind.21. The mounting system of claim 13 wherein said clamping bar comprisesa U-shaped channel opening downwards
 22. The mounting system of claim 21further comprising a load distributing member for interposing betweensaid clamping bar and said support frame to distribute clamping forcesover said support frame.
 23. The mounting system of claim 22 wherein theload distributing member comprises a U-shaped channel opening upwards.